Any idea what the largest port size head a stock TPI intake can bolt too? I have a set of 210s and it appears that is too much port volume as the intake ports are exposed beyond the edges of the intake.

This is the first major obstacle I have come across on my 383 project but it is an expensive one. It appears I have two options, one exchange the heads or two swap intakes.

My builder suggested going carb but I like the TPI and besides I just put over 400 in have it and the plenum ported and I bought a set of ASM runners so I am not real excited about not using the TPI setup.

Thanks in advance for the insight and advice....

 

Porting the plenum was putting the cart ahead of the horse...its the intake baseplate/runners thats the problem with TPI...

you CAN open it up to match many heads.
If you have some patience, some power tools and a place to make a mess, you can use the gasket to mark exactly where the ports are, and how much meat has to come off the intake to make them match.

The heads MAY be too big...meaning the ports extend beyond what the intake can possibly cover. BUT, thats why you match with a gasket before doing or buying anything so you know IF its just a matter of opening the intake ports or if its just not possible.

I cut and port match a few intakes each year and I have had several that were terrible in the beginning. I always "map" the work to be done by measuring every dimension, making a detailed written description and notes on where, how much and how well it ended up. I did one a few months ago that had as much as 6mm to be removed off one side of a single port, and other ports that took less than 0.5mm to be removed. Once the edges match then you can start reaching deep inside to shape the runner and work toward matching the runner volume, which is a bit more tricky. head vol has to be perfect...runners can be slightly off so you have a little latitude in the grinding. Just check the work often and measure again and again..Whats gone is gone forever...

Get the gaskets that you will use and be certain to get the correct side up and mark it with a felt tip pen...and be sure to have the gasket bolted in place exactly so it cannot move while you mark the metal..and document every measurement and go to work. Dremmel makes some sharp cutting bits that will eat aluminum pretty fast but then you have to go back to semi smooth the cut area...not polish, but not hacked up either..
There are You-Tube videos on the DIY port matching.

Have fun !
BTW
the plenum only needs the TB ports matched, the rt side hump ground down flush, and the runner ports matched or siamesed to whatever runner you have picked. If you;re using the stock runners...none of this work will help. Get some SLP or similar that are meaty enough to open up and add about 20% more airflow. Nothing that can be done with the paper thin tubes...If you want a TPI to perform and handle loads in the 5000+ range...its all about moving more air. Then, once you make a substantial difference in the amount of air that it can move, you can bump up the injectors and do a tune to maximize your efforts. I'm currently working on a matched set...plenum, siamesed runners, baseplate AND heads.

 

Based upon the response my assumption is correct; I made a mistake by buying too big of head. What is the maximum size head (200, 195, 180) that has been successfully mated to the base intake? I have to down size the heads and don't want to repeat the same mistake twice.

 

Depends on the brand some are different.
You can make a 1205 work usually...the 1206 youd have to weld material on your base then grind down.
Any 180-195 head should work fine wiht the TPI
Portmatching is always favorable but dont pass up a decent head you can afford if thats a factor it doesnt do that much really unless in a high hp app. Even then youre going after "the last bit".